Method for producing polyamide carpet fibers with improved flame retardancy

ABSTRACT

A method for producing halogen-free, antimony-free and phosphorous-free polyamide fibers is described by incorporating an additive into the polyamide which comprises a vulcanizable mixture of silicones and a catalyst in a thermoplastic matrix. The fibers have improved flame retardancy and are used for the manufacture of carpets.

This is a continuation of application Ser. No. 07/846,510 filed on Mar.6, 1992, now abandoned.

FIELD OF THE INVENTION

The present invention is directed to a method for producing polyamidefibers with improved flame retardancy for the manufacture of fibers forcarpets, more specifically it is directed to the production ofhalogen-free, antimony-free and phosphorous-free polyamide fibers withimproved flame retardancy by incorporating in the polyamide melt avulcanizable mixture of silicones in a thermoplastic polymer matrix.

BACKGROUND OF THE INVENTION

The main approaches to flame retarding polyamides are melt additives,topical finish treatments, and copolymerization with flame resistantmonomers. Melt additives generally include halogenated organic compoundswith high levels of bromine or chlorine. A second component whenhalogenated compounds are employed is antimony trioxide (Sb₂ O₃). Otherpopular elements found in melt additives are phosphorus and molybdenum.The melt additive approach has found limited utility in polyamide fibersdue to the necessary high loadings, discoloration of polymer with somephosphorus and molybdenum compounds, and high smoke generation due tobrominated compounds. Finish treatments generally require high add-onlevels, and many of these lack the durability to cleaning proceduresrequired for polyamide fabrics such as carpeting. Copolymerization is aneffective way to produce flame retardant polymers; however, many ofthese are not considered fiber spinning grade.

U.S. Pat. No. 3,829,400 discloses a flame retardant polyamide fibercomposition using an oxy-tin compound and a halogen as flame retardantagents.

U.S. Pat. No. 4,141,880 discloses a flame retardant nylon compositionwhich contains a condensation product derived from brominated phenol.

U.S. Pat. No. 4,064,298 discloses a flame retardant polyamide fibercontaining zinc brats and an organic halide.

U.S. Pat. Nos. 4,116,931 and 4,173,671 disclose flame retardant fibersand carpets which contain complex salts such as metal borocitrates orborotartrates.

An object of the present invention was to provide a polyamide fiber withimproved flame retardancy which is halogen-free, antimony-free andphosphorous-free.

Another object was a method of producing such polyamide fibers. Stillanother object was a carpet with improved flame retardancy.

SUMMARY OF THE INVENTION

The objects of the present invention could be achieved by incorporatingfrom about 0.05% to 50% by weight, based on the weight of the totalfiber composition, an additive comprising a vulcanizable mixture ofsilicones and a platinum complex catalyst in a thermoplastic polymermatrix. Upon melt spinning, the silicones react to form apseudointerpenetrating polymer network of silicones while leaving thethermoplastic polyamide matrix essentially unaffected, and thus thefiber maintains its thermoplastic character. This network structurewithin the polyamide matrix is thought to give the fiber improved flameretardancy.

A further improvement in flame retardancy of the polyamide fibers couldbe achieved by incorporating together with the silicone additive fromabout 0.1% to 5% by weight, based on the total weight of the fibercomposition, of a zinc salt as a second additive component.

DETAILED DESCRIPTION OF THE INVENTION

Polyamides are well known by the generic term "nylon" and are long chainsynthetic polymers containing amide (--CO--NH--) linkages along the mainpolymer chain. Suitable fiber-forming or melt spinnable polyamides ofinterest for this invention include those which are obtained by thepolymerization of a lactam or an amino acid, or those polymers formed bythe condensation of a diamine and a dicarboxylic acid. Typicalpolyamides include nylon 6, nylon 6/6, nylon 6/9, nylon 6/10, nylon6/12, nylon 11, nylon 12 and copolymers thereof or mixtures thereof.Polyamides can also be copolymers of nylon 6 or nylon 6/6 and a nylonsalt obtained by reacting a dicarboxylic acid component such asterephthalic acid, isophthalic acid, adipic acid or sebacic acid with adiamine such as hexamethylene diamine, methaxylene diamine, or1,4-bisaminomethylcyclohexane. Preferred are poly-ε-caprolactam (nylon6) and polyhexamethylene adipamide (nylon 6/6). Most preferred is nylon6.

The primary additive comprises a vulcanizable or curable mixture ofsilicones and a platinum complex catalyst in a thermoplastic polymermatrix. Such compositions are disclosed in U.S. Pat. Nos. 4,500,688 and4,714,739 the contents of which are herewith incorporated rated byreference. The mixture of silicones generally will comprise a polymericsilicone hydride and a polymeric silicone containing at least oneunsaturated group, preferably a vinyl group. The catalyst is a platinumcomplex preferably derived from chloroplatinic acid and a vinylsiloxane. The vinyl siloxane forms an active complex with the platinum,and the resulting complex is soluble in the silicones to be vulcanized.A thermoplastic polymer serves as the matrix, with suitable polymersbeing, for example, nylon 6, nylon 6/6, nylon 6/9, nylon 6/10, nylon6/12, nylon 11, nylon 12 and copolymers and mixtures thereof. Thepreferred matrix nylons are nylon 6 and nylon 6/6, with the mostpreferred being nylon 6.

The mixture comprising a suitable thermoplastic polymer and avulcanizable silicone is melt mixed for example in an extruder and thenpelletized. To the pellets is added the platinum complex in an amount togive about 1 to 15 ppm platinum by weight of pellets. The pellets withthe added platinum complex are herein referred to as the primaryadditive. Since the primary additive is intended for fiber meltspinning, all ingredients used in the composition must be extrusiongrade. Weight percent of silicones in the primary additive, based on thetotal weight of the primary additive, is in the range of about 5% to20%. A more preferred range is about 10% to 15% based on the weight ofthe primary additive.

The primary additive is then combined with a fiber melt spinning gradethermoplastic polyamide. Fiber melt spinning quality polyamides aregenerally supplied as pellets, thus facilitating easy mixing with theprimary additive pellets. A master blend of the pellets can be madeoff-line and subsequently fed to an extruder, or an in-line dry materialfeeder/blender can be used to dose and blend the pellets, provided thefeeder has good dosing accuracy. The dosing can be done volumetricallyor gravimetrically. Other methods of getting an intimate blend of theprimary additive pellets and the fiber spinning pellets will be obviousto those skilled in the art. The primary additive pellets areincorporated in amounts from about 0.05% to 50% by weight based on thetotal composition weight. A more preferred range is 0.25 to 30 weightpercent of primary additive, and the most preferred range is 1.25 to 20weight percent. The pellet mixture is melt mixed and homogenized forexample in an extruder at temperatures in the range of about 250° C. toabout 300° C., preferably of about 255° C. to about 285° C. At theseelevated temperatures, a reaction is initiated whereby the siliconescombine in situ to form a pseudointerpenetrating polymer network.

A thoroughly homogenized melt stream emerges from the extruder. Fromthis point, the technique of fiber melt spinning is well known in theart. A preferred method is to direct the melt via Dowtherm heatedpolymer distribution lines to the spinning head of the spin beam. Thepolymer melt stream is then metered by a close tolerance gear pump to aspin pack assembly containing a spinnerette plate with severalcapillaries. Polymer melt is extruded or pushed through the capillariesunder pressure to form a multitude of individual filaments.

In a preferred embodiment of this invention, the extruded filaments (orfibers) are quenched with a cross flow of chilled air in order tosolidify the filaments. The filaments are then treated with a finishcomprising a lubricating oil or mixture of oils and antistatic agents.Filaments are then combined to form a yarn bundle which is then wound-upon a suitable package. In a subsequent step, the yarn is drawn andtexturized to form a bulked continuous filament (BCF) yarn suitable fortufting into carpets. A more preferred technique involves combining theextruded or as-spun filaments into a yarn, then drawing, texturizing andwinding a package, all in a single step. This one-step method of makingBCF is referred to in the trade as spin-draw-texturing.

The reaction which is initiated in the melt state, whereby thevulcanizable silicones start to form a pseudointerpenetrating polymernetwork, continues after the fibers are solidified and is essentiallycomplete a few hours after fiber spinning.

Further improvements in the flame retardancy of the polyamide fibers canbe achieved by incorporating effective amounts of a secondary additivein the spinning compositions. The secondary additive is a zinc compoundselected from the group comprising hydrated zinc borate, zinc oxide andzinc hydroxide. A hydrated zinc borate which can retain its water ofhydration up to 290° C. is the preferred compound. Secondary additivelevels are in the range from about 0.1% to 5.0% by weight based on thetotal spinning composition weight. A more preferred range is from about0.25 to 3.0 weight percent. The zinc borate should be in a finelydivided particle size so as not to disrupt fiber spinning processes andso physical properties of the finished fibers are retained. The zincborate would normally be supplied as a concentrate pellet containingfrom about 15 to 30 weight percent of hydrated zinc borate and 70 to 85weight percent of carrier. The carrier comprises a substantial amount ofa polyamide, e.g. nylon 6, and minor amounts of ingredients such asdispersing agents and flow modifiers. The carrier must be compatiblewith the fiber spinning grade polyamide. The zinc borate secondaryadditive concentrate can be incorporated into the spinning compositionusing similar methods as described above for the primary additive.

In addition to the primary additive and zinc borate secondary additiveconcentrate, other various additives can be included in the spinningcomposition. These include, but are not limited to, lubricants,nucleating agents, antioxidants, ultraviolet light stabilizers,pigments, dyes, antistatic agents, soil resists, stain resists,antimicrobial agents, and other conventional flame retardants.

Nylon filaments for the purpose of carpet manufacturing have deniers(denier=weight in grams of a single filament with a length of 9000meters) in the range of about 6 to 35 denier/filament (dpf). Thistranslates to filament diameters in the range from about 25 to 75micrometers. A mere preferred range for carpet fibers is from about 15to 25 dpf.

From here, the BCF yarns can go through various processing steps wellknown to those skilled in the art. The fibers of this invention areparticularly useful in the manufacture of carpets for floor coveringapplications.

To produce carpets for floor covering applications, the BCF yarns aregenerally tufted into a pliable primary backing. Primary backingmaterials are generally selected from the group comprising conventionalwoven jute, woven polypropylene, cellulosic nonwovens, and nonwovens ofnylon, polyester, and polypropylene. The primary backing is then coatedwith a suitable latex material such as a conventional styrene-butadienelatex, vinylidene chloride polymer, or vinyl chloride-vinylidenechloride copolymers. It is common practice to use fillers such ascalcium carbonate to reduce latex costs. In order to further reducecarpet flammability, it is also common to include hydrate materials inthe latex formulation selected from the group comprising aluminumhydroxide, hydrated aluminum oxide, and hydrated aluminum silicates. Thefinal step is to apply a secondary backing, generally a woven jute orwoven synthetic such as polypropylene.

It is preferred for our invention to use a woven polypropylene primarybacking, a conventional styrene-butadiene (SB) latex formulation, andeither a woven jute or woven polypropylene secondary carpet backing. TheSB latex can include calcium carbonate filler and/or one or more of thehydrate materials listed above.

Two test methods have been used to demonstrate the efficacy of thisinvention. The first method is a modification of the well knownMethenamine Pill Test (Department of Commerce Standard DOC FF 1-70).Since results from the standard Pill Test can vary widely, a morestatistically significant method has been developed based on DOC FF1-70. The modified test involves measuring polymer burn time (PBT) of acarpet sample. Since the PBT's do not follow a normal statisticaldistribution, a conventional t-test or analysis of variance cannot beused to examine the significance of differences between sample averages.A Kruskal-Wallis test has been chosen for this purpose for simplicity.

For the modified pill test, dry carpet samples are prepared according tostandard procedures outlined in DOC FF 1-70. Forty measurements of PBTare conducted on two, 9"×9" carpet squares for each sample to be tested,usually a control and an experimental carpet. PBT's for the control andexperimental carpets are assorted in an ascending mode and ranked from 1(shortest PBT) to 80 (longest PBT). The Kruskal-Wallis test evaluatesranks and not the actual experimental results. A parameter H is thencomputed and compared with CHISQ. If H is greater than CHISQ at a chosensignificance level (e.g., 0.05 in our tests), it can be concluded thatthe average PBT's between control and experimental carpets aresignificantly different.

A rigorous treatment of the Kruskal-Wallis statistics can be found inthe National Bureau of Standards Handbook 91.

The second test method is the "Critical Radiant Flux of Floor-CoveringSystems Using A Radiant Heat Energy Source"(ASTM Method E-648), whichwill be referred to herein as simply Radiant Panel Test Method. The testapparatus comprises a gas-fired refractory radiant panel inclined at a30 degree angle to a horizontally mounted test specimen. The paneltemperature is maintained at about 525° C. For our purposes, carpets areburned in a glue down mode. This mode has yielded more reproducibleresults than when carpets are burned over a hair felt pad. Distanceburned (in centimeters) is recorded and critical radiant energy isdetermined in terms of flux (watts/cm²) read from a standard curve. Ahigher flux number indicates a less flammable carpet. At least threespecimens/carpet sample are burned and the results averaged.

The invention is further illustrated by the examples that follow whichare presented to show specific embodiments of the invention, but theseexamples should not be construed as limiting the spirit or the scope ofthe invention. All parts and percentages are by weight (based on thetotal weight of the fiber composition) unless otherwise stipulated.

EXAMPLE 1

Semi-dull BCF nylon 6 carpet yarns were prepared in the followingmanner. A physical blend of the following pelletized components wasprepared: 1) 97.33% of nylon 6 polymer (BASF's Ultramid® BS-700) with arelative viscosity (RV) of 2.7 (measured by comparing, in an Ubbelohdeviscometer at 25° C., flow time of a polymer solution containing onegram of nylon polymer in 100 milliliters of 96% sulfuric acid to flowtime of the pure 96% sulfuric acid); 2) 1.0% of a concentrate comprising30% of a manganese passivated anatase TiO₂ and 70% of a nylon 6 polymerwith about a 1.9 RV; and 3) 1.67% of a mixture comprising 15% ofvulcanizable silicones, a platinum complex catalyst, and nylon 6 polymerwith a 2.7RV.

The above blend was fed to an extruder where it was thoroughly meltedand mixed prior to filament extrusion. The homogenized melt stream wasextruded at a melt temperature of about 270° C. through a spinnerettecontaining 68 capillaries at a rate of about 156 grams/minute. Filamentswere produced to have trilobal shaped cross sections. Filaments werethen combined into a single yarn and wound-up on a package at about 500meters/minute. In a subsequent step, the undrawn or as-spun yarns werethen drawn at about 3.1 times their original length, texturized in asteam medium, and wound-up on a suitable package. The final bulkedcontinuous filament yarn has 68 filaments in the cross section and atotal denier of about 1000 (i.e., 15 dpf). Two of these 1000 denieryarns were then twisted together with 3.5 turns/inch (tpi) to produce a2-ply yarn.

Two-ply (1000/2/68) yarns were autoclave heat set at 132° C. Cut pilecarpets were then made by tufting heat set yarns into a polypropyleneprimary backing on a 1/8 gauge cut pile tufting machine at a stitch rateof 7 stitches/inch and a 1/2" pile height to give 20 ounces/yard² fiberweight. Tufted carpets were dyed a disperse beige color. Dyed carpetswere then divided into two sets. One set was coated with a conventionalSB latex containing calcium carbonate filler and then secondary backedwith a woven jute material. The other set was coated with a similarlatex; however, this set was given a woven polypropylene secondarybacking. A final step was a light tip shearing to remove fuzz. Resultsof flammability tests can be found in Tables I & II.

EXAMPLE 2

A physical blend of the following pelletized components was prepared: 1)95.67% of Ultramid® BS-700 nylon 6; 2) 1.0% of TiO₂ concentrate (samematerial as in Example 1); and 3) 3.33% of silicone-Pt complex-nylon 6mixture used in Example 1. This blend was processed into carpets in amanner consistent with Example 1. Carpet flammability results can befound in Tables I & II.

EXAMPLE 3

A physical blend of the following pelletized components was prepared:1)92.33% of Ultramid® BS-700 nylon 6; 2) 1.0% TiO₂ concentrate (samematerial as in Example 1); and 3) 6.67% of silicone-Pt complex-nylon 6mixture used in Example 1. This blend was processed into carpets in amanner consistent with Example 1. Carpet flammability results are foundin Tables I & II.

EXAMPLE 4

A physical blend of the following pelletized components was prepared andprocessed into carpets in a manner consistent with Example 1: 1) 85.67%of Ultramid® BS-700 nylon 6; 2) 1.0% TiO₂ concentrate (same material asin Example 1); and 3) 13.33% of silicone-Pt complex-nylon 6 mixture usedin Example 1. Carpet flammability results are found in Tables I & II.

EXAMPLE 5

A physical blend of the following pelletized components was prepared andprocessed into carpets in a manner consistent with Example 1, exceptthat the blend was extruded at a melt temperature of 285° C.: 1) 94.0%of Ultramid® BS-700 nylon 6; 2) 1.0% TiO₂ concentrate (same material asin Example 1); and 3) 5.0% of a mixture comprising 10% of vulcanizablesilicones, a platinum complex catalyst, and a nylon 6/6 extrusion gradepolymer. Carpet flammability results can be found in Tables I & II.

EXAMPLE 6

A physical blend of the following pelletized components was prepared andprocessed into carpets in a manner consistent with Example 5: 1) 89.0%of Ultramid® BS-700 nylon 6; 2 ) 1.0% TiO₂ concentrate (same material asin Example 1); and 3) 10.0% of the silicone-Pt complex-nylon 6/6 mixtureused in Example 5. Carpet flammability results can be found in Tables I& II.

EXAMPLE 7 (Comparative)

A physical blend of the following pelletized components was prepared asa control, i.e., without any of the silicone-Pt complex-polyamidemixture: 1) 99.0% of Ultramid® BS-700 nylon 6 and 2) 1.0% TiO₂concentrate (same material as used in Example 1). The blend wasprocessed into carpets in a manner consistent with Example 1. Carpetflammability results are found in Tables I & II.

EXAMPLE 8

A physical blend of the following pelletized components was prepared:1)92.0% of Ultramid® BS-700 nylon 6; 2) 1.0% TiO₂ concentrate (samematerial as in Example 1); 3) 5.0% of the silicone-Pt complex-nylon 6/6mixture used in Example 5; and 4) 2.0% of a concentrate comprising 25%of a hydrated zinc berate (Firebrake® ZB manufactured by U.S. Borax) and75% carrier which is substantially nylon 6.

The blend is processed into carpets in a manner similar to Example 1with the following exceptions:1) extruded at a melt temperature of 285°C.; 2) extrusion rate of about 161 grams/minute; 3) 68 filaments with atotal BCF yarn denier of 1050; 4) cut pile carpet tufted at 7.8stitches/inch to give 25 oz/yd² fiber weight. Carpet flammabilityresults can be found in Tables I & II.

EXAMPLE 9

A physical blend of the following pelletized components was prepared andprocessed into carpets in a manner consistent with Example 8: 1) 85.0%of Ultramid® BS-700 nylon 6; 2) 1.0% TiO₂ concentrate (same material asin Example 1); 3) 10.0% of the silicone-Pt complex-nylon 6/6 mixtureused in Example 5; and 4) 4.0% hydrated zinc berate concentrate (samematerial as used in Example 8). Results of carpet flammability tests canbe found in Tables I & II.

EXAMPLE 10 (Comparative)

This example was prepared in order to show the effects of addinghydrated zinc berate to the fibers, but without the addition of thesilicone-Pt complex-nylon 6/6 mixture. A physical blend of the followingpelletized components was prepared and processed into carpets in amanner consistent with Example 8, except the melt was extruded at atemperature of 270° C.: 1) 97.0% of Ultramid® BS-700 nylon 6; 2 ) 1.0%TiO₂ concentrate (same material as used in Example 1 ); and 3 ) 2.0%hydrated zinc berate concentrate (same material as used in Example 8).Results of carpet flammability tests can be found in Tables I & II.

EXAMPLE 11 (Comparative)

This was another example to show effects of adding hydrated zinc boratewithout the addition of any silicone-Pt complex-nylon 6/6 mixture. Aphysical blend of the following pelletized components was prepared andprocessed into carpets in a manner consistent with Example 10: 1) 95.0%of Ultramid® BS-700 nylon 6; 2) 1.0% TiO₂ concentrate (same material asused in Example 1); and 3) 4.0% hydrated zinc borate concentrate (samematerial as used in Example 8). Results of carpet flammability tests canbe found in Tables I & II.

EXAMPLE 12 (Comparative)

A physical blend of the following pelletized components was prepared asa control, i.e., without any of the inventive additives: 1) 99.0% ofUltramid® BS-700 nylon 6 and 2) 1.0% TiO₂ concentrate (same material asused in Example 1). The blend was processed into carpets in a mannerconsistent with Example 10. Carpet flammability results can be found inTables I & II.

These examples clearly illustrate the effectiveness of the primaryadditive (a vulcanizable mixture of silicones and a platinum complexcatalyst in a thermoplastic polymer matrix such as polyamide) inimproving the flame retardancy of nylon carpet fibers and yarns.Moreover, the PBT data demonstrate that a blend of the primary additiveand a secondary additive such as hydrated zinc berate, has a synergisticeffect in reducing nylon carpet flammability compared with the primaryadditive functioning alone.

Although certain preferred embodiments of the present invention havebeen disclosed herein for illustrative purposes, it will be understoodthat various modifications thereof can be undertaken without departurefrom the basic underlying principles. Aforementioned modifications aretherefore deemed to lie within the spirit and scope of the invention.

                                      TABLE I                                     __________________________________________________________________________    CARPET FLAMMABILITY DATA FROM RADIANT PANEL TESTING (ASTM E-648)                                                     CARPET WEIGHT                          EXAMPLE                       SECONDARY                                                                              FACE FIBER CRITICAL RADIANT            NO.     FLAME RETARDANT ADDITIVES                                                                           BACKING  (OZ/YD*2)  FLUX (WATTS/CM*2)           __________________________________________________________________________    1       1.67% Silicone-Pt complex-nylon 6 mixture                                                           Polypropylene                                                                          20         1.20                        2       3.33% Silicone-Pt complex-nylon 6 mixture                                                           Polypropylene                                                                          20         1.06                        3       6.67% Silicone-Pt complex-nylon 6 mixture                                                           Polypropylene                                                                          20         1.20                        4       13.33% Silicone-Pt complex-nylon 6 mixture                                                          Polypropylene                                                                          20         1.20                        5       5.0% Silicone-Pt complex-nylon 6/6 mixture                                                          Polypropylene                                                                          20         1.20                        6       10.0% Silicone-Pt complex-nylon 6/6 mixture                                                         Polypropylene                                                                          20         1.20                        7       Control, no additives Polypropylene                                                                          20         0.67                        8       5.0% Silicone-Pt complex-nylon 6/6 mixture                                                          Polypropylene                                                                          25         0.98                                2.0% Concentrate of zinc borate                                       9       10.0% Silicone-Pt complex-nylon 6/6 mixture                                                         Polypropylene                                                                          25         1.20                                4.0% Concentrate of zinc borate                                       10      2.0% Concentrate of zinc borate                                                                     Polypropylene                                                                          25         1.20                        11      4.0% Concentrate of zinc borate                                                                     Polypropylene                                                                          25         1.01                        12      Control, no additives Polypropylene                                                                          25         0.56                        __________________________________________________________________________

                                      TABLE II                                    __________________________________________________________________________    CARPET FLAMMABILITY DATA FROM MODIFIED METHENAMINE PILL TEST                                            CARPET AVERAGE                                                                WEIGHT POLYMER          SIGNIFICANTLY               EX-                       FACE   BURN        PARA-                                                                              DIFFERENT FROM              AMPLE                                                                              FLAME RETARDANT                                                                            SECONDARY                                                                             FIBER  TIME        METER                                                                              CONTROL AT                  NO.  ADDITIVES    BACKING (OZ/YD*2)                                                                            (SECONDS)                                                                            CHISQ                                                                              H    0.05 LEVEL                  __________________________________________________________________________    1    1.67% Silicone-Pt                                                                          Jute    20     3.62   3.84 31.80                                                                              YES -- CONTROL IS                complex-nylon 6 mixture                      EXAMPLE NO. 7               2    3.33% Silicone-Pt                                                                          Jute    20     1.86   3.84 43.83                                                                              YES -- CONTROL IS                complex-nylon 6 mixture                      EXAMPLE NO. 7               3    6.67% Silicone-Pt                                                                          Jute    20     4.55   3.84 24.56                                                                              YES -- CONTROL IS                complex-nylon 6 mixture                      EXAMPLE NO. 7               4    13.33% Silicone-Pt                                                                         Jute    20     4.70   3.84 25.23                                                                              YES -- CONTROL IS                complex-nylon 6 mixture                      EXAMPLE NO. 7               5    5.0% Silicone-Pt                                                                           Jute    20     3.18   3.84 35.13                                                                              YES -- CONTROL IS                complex-nylon 6/6 mixture                    EXAMPLE NO. 7               6    10.0% Silicone-Pt                                                                          Jute    20     3.27   3.84 33.22                                                                              YES -- CONTROL IS                complex-nylon 6/6 mixture                    EXAMPLE NO. 7               7    Control, no additives                                                                      Jute    20     17.38  --   --   CONTROL SAMPLE              8    5.0% Silicone-Pt                                                                           Jute    25     0.65   3.84 48.53                                                                              YES -- CONTROL IS                complex-nylon 6/6 mixture                    EXAMPLE NO. 12                   2.0% Concentrate of                                                           zinc borate                                                              9    10.0% Silicone-Pt                                                                          Jute    25     0.38   3.84 53.20                                                                              YES -- CONTROL IS                complex-nylon 6/6 mixture                    EXAMPLE NO. 12                   4.0% Concentrate of                                                           zinc borate                                                              10   2.0% Concentrate of                                                                        Jute    25     7.14   3.84  6.31                                                                              YES -- CONTROL IS                zinc borate                                  EXAMPLE NO. 12              11   4.0% Concentrate of                                                                        Jute    25     8.07   3.84  2.11                                                                              NO -- CONTROL IS                 zinc borate                                  EXAMPLE NO. 12              12   Control, no additives                                                                      Jute    25     11.08  --   --   CONTROL SAMPLE              1    1.67% Silicone-Pt                                                                          Polypropylene                                                                         20     2.55   3.84 36.58                                                                              YES -- CONTROL IS                complex-nylon 6 mixture                      EXAMPLE NO. 7               2    3.33% Silicone-Pt                                                                          Polypropylene                                                                         20     1.06   3.84 50.23                                                                              YES -- CONTROL IS                complex-nylon 6 mixture                      EXAMPLE NO. 7               3    6.67% Silicone-Pt                                                                          Polypropylene                                                                         20     1.56   3.84 42.63                                                                              YES -- CONTROL IS                complex-nylon 6 mixture                      EXAMPLE NO. 7               4    13.33% Silicone-Pt                                                                         Polypropylene                                                                         20     1.53   3.84 41.69                                                                              YES -- CONTROL IS                complex-nylon 6 mixture                      EXAMPLE NO. 7               5    5.0% Silicone-Pt                                                                           Polypropylene                                                                         20     1.22   3.84 45.37                                                                              YES -- CONTROL IS                complex-nylon 6/6 mixture                    EXAMPLE NO. 7               6    10.0% Silicone-Pt                                                                          Polypropylene                                                                         20     1.21   3.84 49.28                                                                              YES -- CONTROL IS                complex-nylon 6/6 mixture                    EXAMPLE NO. 7               7    Control, no additives                                                                      Polypropylene                                                                         20     10.75  --   --   CONTROL                     __________________________________________________________________________                                                      SAMPLE                  

I claim:
 1. A method for producing a flame-retardant thermoplasticpolymer carpet or textile fiber comprising the steps of:(a) forming apolyamide mixture having (i) at least about 80% by weight of apolyamide, wherein at least 90% of the polyamide is at least one nylonselected from the group consisting of nylon 6, nylon 6/6, copolymersthereof, and combinations thereof, and (ii) a vulcanizable additivecontaining (1) a thermoplastic matrix polymer, (2) silicones in anamount between about 5% to about 20% based on the total weight of thevulcanizable additive, and (3) a platinum complex catalyst, saidadditive being present in the polyamide mixture in an amount betweenabout 0.05% to about 20% by weight of the polyamide mixture to obtainless than about 1.0% by weight of said silicones in the polyamidemixture sufficient to render the polyamide more flame retardant than thepolyamide is without the additive; (b) melt blending the polyamidemixture at a temperature of from about 250° C. to about 300° C. to forma melt-blend of the polyamide and the additive; (c) melt spinning themelt-blend from step (b) into fibers having a denier per filament fromabout 6 to about 35; (d) drawing the fibers; and (e) treating the drawnfibers in a crimping device to impart texture and bulk thereto.
 2. Themethod of claim 1, wherein step (a) is practiced so that said additiveis present in the polyamide mixture in an amount from 0.25% to about 20%by weight of the polyamide mixture.
 3. The method of claim 1, whereinthe additive contains silicone in an amount from about 5% to about 20%by weight of the additive.
 4. The method of claim 1, wherein step (a)further comprises adding a zinc compound to the polyamide mixture in anamount from about 0.1% to about 5.0% by weight of the polyamide mixture.5. The method of claim 4 wherein the zinc compound is selected from thegroup consisting of:zinc borate; zinc oxide; zinc hydroxide; andmixtures thereof.
 6. The method of claim 3, wherein step (a) furthercomprises adding a zinc compound to the polyamide mixture in an amountfrom about 0.1% to about 5.0% by weight of the polyamide mixture.
 7. Themethod of claim 6 wherein the zinc compound is selected from the groupconsisting of;zinc borate; zinc oxide; zinc hydroxide; and mixturesthereof.
 8. A method for producing a flame-retardant thermoplasticpolymer carpet or textile fiber comprising the steps of:(a) forming apolyamide mixture having (i) at least about 80% by weight of apolyamide, wherein at least 90% of the polyamide is at least one nylonselected from the group consisting of nylon 6, nylon 6/6, copolymersthereof, and combinations thereof, and (ii) a vulcanizable additivecontaining (1) a thermoplastic matrix polymer, (2) silicones in anamount between about 5% to about 20% based on the total weight of thevulcanizable additive, and (3) a platinum complex catalyst, saidadditive being present in the polyamide mixture in an amount betweenabout 0.05% to about 20% by weight of the polyamide mixture to obtainless than about 0.5% by weight of said silicones in the polyamidemixture sufficient to render the polyamide more flame retardant than thepolyamide is without the additive; (b) melt blending the polyamidemixture at a temperature of from about 250° C. to about 300° C. to forma melt-blend of the polyamide and the additive; (c) melt spinning themelt-blend from step (b) into fibers having a denier per filament fromabout 6 to about 35; (d) drawing the fibers; and (e) treating the drawnfibers in a crimping device to impart texture and bulk thereto.
 9. Themethod of claim 8, wherein step (a) is practiced so that said additiveis present in the polyamide mixture in an amount from 0.25% to about 20%by weight of the polyamide mixture.
 10. The method of claim 8, whereinthe additive contains silicone in an amount from about 5% to about 20%by weight of the additive.
 11. The method of claim 8, wherein step (a)further comprises adding a zinc compound to the polyamide mixture in anamount from 0.1% to about 5.0% by weight of the polyamide mixture. 12.The method of claim 11, wherein the zinc compound is selected from thegroup consisting of zinc borate, zinc oxide, zinc hydroxide, andmixtures thereof.
 13. The method of claim 10, wherein step (a) furthercomprises adding a zinc compound to the polyamide mixture in an amountfrom 0.1% to about 5.0% by weight of the polyamide mixture.
 14. Themethod of claim 13, wherein the zinc compound is selected from the groupconsisting of zinc borate, zinc oxide, zinc hydroxide, and mixturesthereof.